Control Housing Cover: Installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2008 Volkswagen Jetta, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

To prevent injuries from shavings, wear protective goggles and protective clothing.

-- Remove the remainder of the sealant from the cylinder block, upper oil pan and control housing cover, for example using a rotating plastic brush.

CAUTION:

Make sure that no sealant residue enters the engine.

-- Clean the sealing surfaces of the cylinder block, upper oil pan and control housing cover, they must be free of oil and grease.

-- Replace the seals -1 and 2-.

Fig 1: Identifying Sealing Rings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Cut the sealant tube nozzle at the front mark (nozzle diameter: approximately 1 mm).

Fig 2: Identifying Scissors To Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The control housing cover must be installed within 5 minutes after application of the sealant.

-- Apply the sealant bead -A- onto the control housing cover as shown.

Fig 3: Identifying Sealant Bead To Apply On Control Housing Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

The sealant bead must be 1.5 to 2.0 mm thick.
Pay special attention to the course of the sealant bead in the area -arrow-.

-- Install the control housing cover so that the alignment sleeves engage in the bores in the cylinder block.

-- Install all bolts hand tight.

-- First, tighten all the bolts -3- to the cylinder block and the upper oil pan to 10 Nm.

Fig 4: Identifying Removal Points For Control Housing Cover -1- From Cylinder Block -2- And From Upper Oil Pan -3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Finally, tighten the bolts to the cylinder block and the upper oil pan to 25 Nm.

-- Wipe off any sealant, which has leaked out.

-- Drive the alignment sleeves in until seated, if necessary.

-- Install a new crankshaft seal. Refer to CRANKSHAFT SEAL, TRANSMISSION SIDE .

The rest of the installation follows the reverse of the removal procedures. When doing this note the following:

Install the brake booster vacuum pump. Refer to BRAKE BOOSTER VACUUM PUMP .
Install the cylinder head. Refer to CYLINDER HEAD .
Install the flywheel/drive plate. Refer to DRIVE PLATE .
Remove the locking pin T40069 from the rear of the cylinder block and install the locking bolt.
Fill the coolant system. Refer to DRAINING AND FILLING .